nalco water – tissue intelligence 3d trasar™ for …...– 3 yrs. process engineer &...

Nalco Water – Tissue Intelligence 3D TRASAR™ for Yankee Dryers

Bruce BarkerOctober 3rd, 2019

Biography

Bruce Barker: Director of Technical Consulting – Board, Specialty, Utilities, AutomationEducation• BS Chemical Engineering – University of Washington• BA English Literature – University of WashingtonIndustry Experience• 18 yrs. Nalco Company

– 11 yrs. District Sales Manager – Dallas / Shreveport Area– 6 yrs. District Representative to Area Manager – Board and Packaging

• 9 yrs. Paper Industry Manufacturing– 3 yrs. Process Engineer & Production Engineer– 6 yrs. RDF Chemical Sales Representative

Expertise• Wet End Chemistry, RDF, Sizing, Dry Strength, Wet Strength, Contaminant Control, Filler Loading,

Application Best Practices, Sole Source Transitions, Data Analysis

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Introduction• What is TRASAR™?

– Chemistry– History / Evolution of 3D TRASAR™

• Yankee Dryer – Symptoms of Poor Performance– Deposit, Chemical and Monitoring components

• Methods for Monitoring and Treatment• Case Study - 3D TRASAR™ for Yankee Dryers• Nalco Water - Digital Solutions Vision

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Emission

Excitation

Program overview – Nalco Water Trasar™WHAT IS TRASAR™

– TRASAR™ is a Nalco Water patented, tracer material developed in the 1980’s

– Non-reactive chemical species• Totally inert, non-volatile, thermally stable

molecules– Precisely measurable based on its

fluorescence• Can accurately measure the tracer element to

the ppb level• Measurement is based entirely upon

concentration of chemical, and not on the mass balance of chemical

TRASAR™ is like having a bar code on a molecule

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Cooling Water TRASARAutomatic Dosage Control

Boiler TRASARAutomatic Dosage Control

3D TRASAR TechnologyPerformance Monitoring & Advanced ControlCharting, Reporting, & Web Alarms

System Assurance Center24/7 Remote Monitoring & Alarm Response

3D TRASAR Technology for DAF AutomationPerformance Monitoring & Advanced Control

Plant Resource OptimizerSystem Flow Diagrams (Web)

Nalco enVisionDashboards, charting, & reporting (Web)

Next Generation of Cooling WaterInformatics – ID Benchmark Opportunity

3D TRASAR Solid Cooling Water TechnologyAutomatic Dosage Control

3D TRASAR Technology for MembranesPerformance Monitoring & Advanced Control

3D TRASAR Boiler TechnologyPerformance Monitoring & Advanced Control

1988 1991 2004 2007 2008 2011 2012 2014 2016 2018

3D TRASAR Boiler - Hardness Response ProgramFully automated hardness monitoring and corrective action & communication

3D TRASAR Technology for High Pressure BoilersHigh purity systems including pH / PO4 programs

Commitment to Innovation

Nalco Water BioAssuranceMake sure biocide feeds are never missed

3D TRASAR Solid Cooling Water Technology: Advanced Biocide ProgramNon-pressurized solid biocide dispenser system

41,000 Total Shipped Globally

3D TRASAR™ – LATEST GENERATION• 4th generation Fluorometers & Controllers• TRASAR Excitation Advancements

• Fluorescent bulbs to LEDs• Additional sensors

• NCSM• pH• Conductivity

• Advanced software for automated boiler treatment and control• CoPhos Control algorithms• Front End or Back End Control

• Communication capabilities• Alarms – enVision – ECOLAB3D

• CASSADY Boiler Controller in development

• Innovative ways to use TRASAR in mills

Nalco Water Corrosion Stress Monitor Cond

pH

FluorometerController

What are the Consequences of Poor Water Treatment?

• Survey of 20 Boiler Repair Companies indicates that 82% of Boiler Repairs are related to poor water treatment.

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Nalco Corrosion Stress Monitor™

What is the Nalco Corrosion Stress Monitor? The Corrosion Stress Monitor, in conjunction with 3D

TRASAR Boiler Automation, measures and controls boiler feedwater corrosivity

How is this unique? Direct Measurement of Corrosivity - Direct measure of

feedwater system corrosivity at operating temperature and pressure

Corrosion Protection - Maximize corrosion protection with continuous monitoring and corrective response to system stress

Real Time Visibility - Provides Real Time visibility of oxygen scavenger performance and corrosion protection

Immediate and Accurate - Controlled and precise treatment based on feedwater system demand.

Feed

Wat

er C

orro

sion

Stre

ss M

onito

r (m

V) +300

+200

+100

0

-100

-200

-300

-400

-500

-600

0.8 mpy

0.2 mpy

Pitting

Close to Pitting Zone High General Corrosion

Rate

Low General Corrosion Zone

Operating Range for Corrosion Protection *

* Refer to specific control ranges for operating conditions and oxygen scavenger type

Yankee Dryer Performance

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Symptoms of Poor Yankee Performance• Wet streaks• Random coating patchiness• Chatter• Reduced drying capacity• Increased ∆P at constant blowthrough

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When these symptoms become apparent, it is too late,Quality and production have already been affected!

Components of Yankee Performance

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Yankee Dryer Performance

DepositComponent

ChemistryComponent

MonitoringComponent

Operational Consideration

• One ppm of CO2 dissolved in 140oF pure condensate will lower the pH from 6.5 to 5.5

• Oxygen dissolved in 140oF pure condensate is 6-10 times more corrosive to iron than its molar equivalent of CO2

• When both gases are present together, the resultant corrosion rate is 10-40 times greater than the sum of the corrosion rates of the two acting separately

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Carbon Dioxide and Oxygen entering through the feedwateror as in-leakage are incredibly corrosive to the Yankee.

ChemistryComponent

Operational Consideration

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The concentration of these components is dynamic sotreatment and control is paramount to preventing corrosion

ChemistryComponent

Operational Consideration

• The velocity of the condensate will be at it's highest and the relative pressure at the lowest in the Yankee Dryer soda straw

• The physics dictate this is where corrosion by-product deposition will occur

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Soda Straw WallIron deposit

DepositComponent

Operational ConsiderationInstrument or Test Limitation

pH Indirect measurement of only one of the components of corrosion.

Dissolved Oxygen Oxygen stays with the steam, not the condensate.

Conductivity Single component measurement of boiler water carryover.

Particle Monitor Slow sample time that can not be used to control chemicalprogram.

Millipore Test Requires 5 fps sample flow to be accurate.

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A comprehensive monitoring and control system is needed to manage the performance of this asset.

MonitoringComponent

Components of Yankee Performance

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Yankee Dryer Performance

DepositComponent

ChemistryComponent

MonitoringComponent

Deposit Component

Chemistry Component

MonitoringComponent

Measures every component of corrosion• NCSM measures active corrosion

through at temperature ORP• pH• Conductivity• TRASAR

Corrosion inhibitor controlled by PID, chemistry fed according to conditions• PID control allows the dampening of

events• Alarms and data collection provide

diagnostics of the system

Through proper monitoring, program automation, and diagnostic evaluation; corrosion by-products are minimized eliminating the source of deposition

Components of Yankee Performance

Simplified Diagram: 3D TRASAR™ for Yankee

• Standard Boiler Treatment– Internal Treatment– Oxygen Scavenger– Condensate Treatment

• 3D TRASAR™ for Yankee– Satellite treatment of

condensate for Yankee, with controller

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pH Control – Before and After

Manual Control

Control – NCSM™ Corrosivity

Why do you care?Time pH NCSM Reading Soluble Iron (Fe+2)

8:30 am 9.01 -702 0 ppbAmine Off 8:40 am 9.01 -702 0 ppb

9:40 am 6.95 -640 0 ppb10:45 am 6.64 -625 1 ppb11:45 am 6.54 -620 1 ppb1:00 pm 6.2 -590 3 ppb3:00 pm 6.01 -560 10 ppb

Amine On 3:15 pm5:00 pm 9.0 -702 0 ppb6:30 pm 8.9 -700 0 ppb

The passivated layer in a Yankee Dryer is not robust!

CASE STUDY

Tissue MachineMid-West USA

3D TRASARTM for Yankee Dryer

SITUATION:A Tissue Machine incurred 5 unscheduled maintenance outages over 7 months due to poor tissue quality created by Yankee dryer soda straw flow issues. In addition to downtime, quality of the tissue produced was being compromised.

SOLUTION:The mill implemented a local condensate treatment on the Yankee Dryer with Nalco Water 3D TRASAR™ for Boiler control logic. By maintaining accurate feed rate, pH and NCSM parameters, the corrosion and plugging issues were eliminated.

Overview of Yankee Intelligence

Yankee Operations SolutionOPTIMIZE TISSUE PRODUCT QUALITY, MAXIMIZE MACHINE EFFICIENCY & REDUCE COST OF OPERATION

MAXIMIZE PERFORMANCEDRIVE RESULTS

System Assurance

Center

System-Specific

Collected Data

Modeling Value

Calculations

OPTIMIZEDCOSTS

OPTIMIZED TISSUEQUALITY

ENHANCEDPRODUCTIVITY

Enterprise Metrics / Global Benchmarking

Mill Control

Nalco Water Rep Connectivity

Yankee Operation

• Nalco Water Data• Customer Yankee

Operation data• Customer Tissue product

Quality data• Wet End operation data

Predictive Analytics

Monitoring-Chatter

Prevention

Performance Dashboard

Insights into Controllable actionsOUR JOURNEY

Nalco Water – Tissue Intelligence 3D TRASAR™ for Yankee Dryers

Bruce BarkerOctober 3rd, 2019